LEXUS ES300 2005 Repair Manual

B53740
B53741
B53739
- REAR SUSPENSIONSTRUT ROD ASSY REAR
27-19
2401 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Connect the strut rod (inner side) with the bolt.
Torque: 113 NVm (1,150 kgfVcm, 83 ftVlbf)
HINT:
While fixing the nut, turn the bolt.
4. STABILIZE SUSPENSION (See page 27-10)
5. FULLY TIGHTEN STRUT ROD ASSY REAR
(a) Fully tighten the bolt.
Torque: 113 NVm (1,152 kgfVcm, 83 ftVlbf)
HINT:
While fixing the nut, turn the bolt.
(b) Install the parking brake cable with the bolt and nut.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
6. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
7. INSPECT REAR WHEEL ALIGNMENT (See page 27-3)

190SE-01
A79718
A86236Terminal 50Terminal C
BodyBattery
A86239Terminal CBattery Disconnect
A86238
Disconnect
Body
Battery
- STARTING & CHARGINGSTARTING SYSTEM (3MZ-FE)
19-1
2333 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STARTING SYSTEM (3MZ-FE)
INSPECTION
1. INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
prevent burnout of the coil.
(a) Perform the pull-in test.
(1) Remove the nut, then disconnect the lead wire from
terminal C.
(2) Connect the battery to the repair service starter kit
as shown in the illustration. Check that the clutch
pinion gear is extended.
If the clutch pinion gear does not move, replace the starter mag-
netic switch.
(b) Perform the hold-in test.
(1) Disconnect the negative (-) lead from terminal C
with the lead wire disconnected from terminal C.
Check that the clutch pinion gear remains ex-
tended.
If the clutch pinion gear returns inward, replace the starter mag-
netic switch.
(c) Check the operation.
(1) Disconnect the negative (-) lead from the switch
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return inward, replace the
starter magnetic switch.

A79718
A86237
Terminal 30
Terminal 50Battery Ammeter
Body
A86241
Battery
Ohmmeter 19-2
- STARTING & CHARGINGSTARTING SYSTEM (3MZ-FE)
2334 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C. Make sure that
the lead is not grounded.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current: 90 A or less at 11.5 V
If the current is not as specified, replace the starter.
2. INSPECT STARTER RELAY ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1W
(Apply battery voltage to terminals 1 and 2
If the result is not as specified, replace the starter relay.

190SF-01
A86242: Specified torque
9.0 (92, 79 in.Vlbf)
Battery Clamp Sub-assy
Battery
Battery Tray
VSV Connector
Air Cleaner Inlet
Assy
Air Cleaner Inlet
No. 1Air Cleaner Case
Sub-assyAir Cleaner Filter
Element Sub-assyAir Cleaner Cap
Sub-assy Mass
Air Flow Meter
Connector Vacuum Hose
5.0 (51, 44 in.Vlbf)
x2
x3
5.0 (51, 44 in.Vlbf)
5.0 (51, 44 in.Vlbf)
Air Cleaner Hose
No. 1
5.0 (51, 44 in.Vlbf)
N´m (kgf´cm, ft´lbf)Vacuum Hose
Air Cleaner Bracket
7.5 (76, 66 in.Vlbf)x2
Clip
Radiator Lower Air Deflector x7
Clip
3.5 (36, 31 in.Vlbf)
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-3
2335 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
STARTER ASSY (3MZ-FE)
COMPONENTS

A86243
Starter Field Frame
Assy Starter Commutator End Frame Assy
Starter Magnetic Switch AssyDrive Housing
Starter Bearing Cover
Starter Armature Assy
Washer
Starter Drive Housing Assy
(w/ Clutch & Drive Lever
& Center Bearing)
7.5 (76, 66 in.Vlbf)
10 (102, 7)

Snap Ring

Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
Starter Armature Plate
Planetary GearStarter Assy
Starter Connector
x237 (380, 26)
9.8 (100, 7)
x2
6.0 (61, 53 in.Vlbf)
x2 19-4
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2336 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

190SG-01
A86308
A86245
(a)
(b)
(c)
(b)
(c)
A81652
(a)
(b)
(b)
(b)
(b)
(c)
(c)
(d)
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-5
2337 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE RADIATOR SIDE DEFLECTOR RH
(a) Remove the 8 clips, then remove the radiator lower air de-
flector.
2. REMOVE AIR CLEANER INLET ASSY
(a) Remove the wire harness clamp.
(b) Remove the 2 vacuum hoses from the hose clamp.
(c) Remove the 2 bolts, then remove the air cleaner inlet.
3. REMOVE BATTERY
4. REMOVE BATTERY TRAY
5. REMOVE AIR CLEANER ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the 4 vacuum hoses.
(c) Loosen the 2 air cleaner cap bolts.
(d) Loosen the air cleaner hose clamp bolt, then remove the
air cleaner cap.
(e) Remove the air cleaner filter element.

A86307
(f)
(g)
(h)
(h)(h)
(i)(i)
A78525
A78526
A78527
Terminal Cap
(a)
(c) 19-6
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2338 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Disconnect the VSV connector.
(g) Disconnect the vacuum hose.
(h) Remove the 3 bolts.
(i) Remove the wire harness from the 2 wire harness clamps,
then remove the air cleaner case.
6. REMOVE AIR CLEANER BRACKET
(a) Remove the 2 bolts, then remove the air cleaner bracket.
7. REMOVE AIR CLEANER INLET NO.1
(a) Remove the bolt, then remove the air cleaner inlet No. 1.
8. REMOVE STARTER ASSY
(a) Disconnect the starter connector.
(b) Open the terminal cap.
(c) Remove the nut, then disconnect the starter wire.

A78528
(d)
(d)
A78525
1
2
A86248
1
2
3
Air Cleaner
CaseAir Cleaner
Inlet No. 1
(b)
(d)
(e)
(b)
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-7
2339 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Remove the 2 bolts, then remove the starter.
9. INSTALL STARTER ASSY
Torque:
37 NVm (380 kgfVcm, 26 ftVlbf) for bolt
9.8 NVm (100 kgfVcm, 7 ftVlbf) for nut
10. INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
11. INSTALL AIR CLEANER BRACKET
(a) Install the air cleaner bracket with the 2 bolts. Using sev-
eral steps, tighten the bolts uniformly in the sequence
shown in the illustration.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
12. INSTALL AIR CLEANER ASSY
(a) Install the air cleaner case to the air cleaner inlet No. 1 as
shown in the illustration.
(b) Install the wire harness to the 2 wire harness clamps.
(c) Using several steps, tighten the 3 bolts uniformly in the
sequence shown in the illustration.
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
(d) Connect the vacuum hose.
(e) Connect the VSV connector.
(f) Install the air cleaner filter element.
(g) Install the air cleaner cap, then tighten the air cleaner
hose clamp bolt.
(h) Tighten the 2 air cleaner cap bolts.
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
(i) Connect the 4 vacuum hoses.
(j) Connect the mass air flow meter connector.

19-8
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2340 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. INSTALL BATTERY TRAY
14. INSTALL BATTERY
Torque:
9.0 NVm (92 kgfVcm, 79 in.Vlbf) for bolt
3.5 NVm (36 kgfVcm, 31 in.Vlbf) for nut
5.4 NVm (55 kgfVcm, 48 in.Vlbf) for terminal
15. INSTALL AIR CLEANER INLET ASSY
Torque: 5.0 NVm (55 kgfVcm, 44 in.Vlbf)
16. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
17. INSTALL RADIATOR SIDE DEFLECTOR RH
18. SYSTEM INITIALIZATION (See page 19-15)

190SH-01
A79718
A79719
A79720
A79721
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-9
2341 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE STARTER MAGNETIC SWITCH ASSY
(a) Remove the nut, then disconnect the lead wire from termi-
nal C.
(b) Remove the 2 screws which secure the starter magnetic
switch to the starter drive housing.
(c) Remove the starter magnetic switch.
(d) Remove the return spring and plunger from the starter
drive housing.
2. REMOVE STARTER FIELD FRAME ASSY
(a) Remove the 2 through bolts, then pull out the field frame
together with the starter commutator end frame.
(b) Remove the starter field frame from the starter commuta-
tor end frame.